Programmed welding with controlled rectifier welding power source



3,350,538 CONTROLLED RECTIFIER ING POWER SOURCE Oct. 31, 1967 A. E. JOHNSON PROGRAMMED WELDING WITH WELD Filed April III.

l N V E NTOR ARTHUR E. JOHNSON United States Patent Oflfice 3,350,538 PROGRAMMED WELDING WITH CONTROLLED RECTIFIER WELDING POWER SOURCE Arthur E. Johnson, Elkhorn, Wis., assiguor to I-larnischfeger Corporation, West Milwaukee, Wis., a corporation of Wisconsin Filed Apr. 7, 1964, Ser. No. 358,044 2 Claims. (Cl. 219-137) This invention relates to a controlled rectifier power source, and more specifically to a power source which produces an alternating polarity, square wave current for arc welding. The power source includes a control circuit for rapidly switching positive and negative current pulses to the welding electrode to modify the electrical characteristics of the arc, thereby providing more precise electrical control of the welding arc than was heretofore possible. This power source can be used with a Wide variety of electrodes, and for a large number of different welding applications, because the duration and amplitude of the positive and negative current pulses of the output can be changed easily to fit particular welding conditions. This power source inherently provides a steep wave front, because it employs high-speed controlled rectifiers for switching from positive to negative polarity current condition. Arc reignition, therefore, is accomplished without requiring an auxiliary arc reignition circuit, since the voltage switches from full negative to full positive in less than 20 microseconds. For some electrode wires, the rapid switching time is not required, but it has been discovered that certain D.C. electrodes, which could not be used on AC. can now be used successfully with the power source of the invention. Magnetic arc blow is eliminated, Weld penetration is closely controlled, and the weld deposition rate is substantially increased .as compared to direct current reverse polarity welding by the Welding method of the invention.

Various circuits have been proposed in the past to provide a positive and negative half cycle in an AC. power source, but when applied to arc welding, auxiliary means have been required for starting and reigniting the arc each half cycle. In addition, most of these other power sources have been used only for non-consumable electrode arc welding, and usually with argon shielding gas.

The present invention specifically contemplates the use of two constant potential, D.C. power supplies connected into a control circuit at opposite polarities in such a way that they can be connected to the Welding electrode sequentially to produce predetermined adjustable, square wave current pulses at variable, predetermined voltages governed by the control settings or program of the control circuit. The control circuit of the invention includes a positive and negative half, and each includes a plurality of small parallel turn-off controlled rectifiers, circuits associated with a plurality of parallel, larger load current controlled rectifier circuits, each load current controlled rectifier having its gate associated with the secondary winding of a pulse transformer, and through a commutating capacitor, connected to one of the respective turn-off controlled rectifiers. Each pulse transformer is connected to receive a signal from a master load current controlled rectifier in the opposite polarity side of the circuit. When the master load current controlled rectifier is turned off by its associated turn-off SCR, a pulse is generated to turn on the opposite polarity master load current controlled rectifier. The back bias voltage for turning a load SCR off is provided by the discharge of a capacitor. The capacitor discharge is caused by the turn-n of the smaller turn-01f controlled rectifiers, which are signalled from. a trigger pulse transformer in a smaller trigger circuit.

The interconnection of the positive and negative load 3,350,538 Patented Oct. 31, 1967 current controlled rectifiers in the manner described is an important feature of the invention. The positive and negative halves. of the load circuit are electrically interconnected so that the turn-off signal for the positive load cur rent controlled rectifiers provides the turn-on signal for the negative load current controlled rectifiers, and vice versa, thereby enabling rapid switching. A plurality of the load current controlled rectifier circuits are paralleled in the circuit for greater current carrying capacity. It is possible to parallel any required number of load current controlled rectifiers when they are arranged in the manner of the invention.

Each of the load current controlled rectifiers has a smaller turn-off controlled rectifier associated with it in the circuit. The turn-off controlled rectifiers cause their respective load current controlled rectifiers to turn off. The circuit is arranged so that each turn-01f controlled rectifier is triggered by a signal from ,a pulse transformer on the trigger circuit network. When the turnoff controlled rectifiers conduct, they apply a charged commutating capacitor to their respective load current controlled rectifiers, back biasing them for the time required for charge carriers to clear the SCR junctions. This action also enables a pulse transformer to provide a turnon pulse for the opposite polarity load current controlled rectifiers. This action is sequential, that is, the back biasing must come before opposite polarity turn on, thereby preventing both polarities from conducting at the same time.

One of the problems with the use of controlled rectifiers for controlling the amplitude and duration of any constant potential power source is the fact that the controlled rectifier can be turned on very readily, but requires either a back bias voltage, or a complete switchoff of its load current to turn it off.

The controlled rectifier welding power source of the invention switches from one polarity to the opposite and comes to peak voltage so rapidly that a square wave shape is produced. The adjustment of the trigger circuit provide means to control the duration of each positive and negative current pulse produced by the power source. The duration of the positive and negative half cycles can be varied independently, and each successive pulse can be varied according to any desired program sequence to meet specific welding requirements. The turn-01f of one polarity of the composite power source automatically triggers the turn-on of the opposite polarity conducting period. The voltage of each power source can be varied independently also, as well as the current, by adjusting the individual power source settings.

The independent and infinitely variable controlled output has enabled the development of new welding processes utilizing the square wave current output.

In prior arc welding methods, attempts have been made to solve the AC. welding arc instability problem by means of special electrode formulations, auxiliary D.C. power supplies and other are restrike means. Such devices were required, because the power source wave forms were sinusoidal. With such a wave form, the potential across the arc remains low for a long enoughv period to extinguish the are. With the applicants square wave, the potential passes through zero so quickly that are reignition takes place readily. A.C. Welding with bare steel electrodes is made possible with the circuit of the invention with no added emissive materials, auxiliary are starting circuit, or other are restrike means.

In addition, proper sequence programming of the power pulses has made possible a completely new concept in welding methods. Prior to this invention, a relatively skilled manual weldor was required to perform good quality out-of-position welds. By using the programmed sequence of the invention, even an amateur can make good out-of-position welds, either vertical or overhead.

The amateur'weldor simply follows instructions for setting the control circuit to a particular control sequence and strikes an are, maintaining the arc electrode at a predetermined position and direction of travel with regard to the workpiece. The power source automatically provides the proper current and heat input to the work as welding progresses. In effect, the programmed power source accomplished the welding results which are otherwise accomplished by the weaving motion characteristic of an expert weldor. Proper current peaks are provided for driving the metal home under those conditions when it is necessary, and the circuit may also be adjusted for effective cathodic cleaning.

The drawings furnished herewith illustrate the best mode presently contemplated for carrying out the invention.

In the drawings:

FIGURE 1 is a schematic diagram showing the power source used in the method of the invention; and

FIGURE 2 is a voltage/time graph illustrating the rapid rise time characteristic and the infinitely variable control which can be programmed into the power source of FIGURE 1.

The controlled rectifier power source of the invention basically comprises a positive DC. power source 1, a negtive DC. power source 2, and a control circuit 3 for alternately switching the load between power sources, rapidly, in any predetermined schedule. The power sources 1 and 2 are each standard constant potential transformer rectifier units, rated at 600 amps. full duty cycle and '55 volts open circuit. Units 1 and 2 are provided with voltage and amperage adjustment means, as indicated by the arrows in FIG. 1. The adjustment means may take the form of program control units of any well known type, such as a pre-programmed tape connected to an electric servomotor system which automaticallyadjusts the corresponding power source in response to signals from the program means. Other electro-mechanical means can be used to program the voltage and current supplied from the power sources 1, 2 to meet specific welding conditions, and their use in combination with applicants invention is readily apparent to those skilled in the art. Power source 1 is connected with its negative pole 4 to common ground 5, while power source 2 has its positive pole 6 connected to ground 5. By connecting the power sources 1 and 2 in this manner to control cir' cuit 3, a square wave A.C. can be synthesized from the rapid alternate on-ofi switching of the DC. power sources 1 and 2 through a welding electrode 7 with which the power sources are connected through the control circuit 3.

The control circuit 3 comprises a conventional pulse transformer trigger circuit 8, such as shown in FIG. 1, and a novel controlled rectifier switching circuit 9.

The switching circuit 9 is an important feature of the invention, and provides means to positively switch the load between power sources 1 and 2 at switching speeds in the order of five to twenty microseconds. The switching circuit 9 fully utilizes the high switching speeds of controlled rectifiers so that any desired program of square waves, variable width A.C. pulses, examples of which 1 are shown in FIG. 2 of the drawings, may be formed.

In the following description of the control circuit 3,. the controlled rectifiers will be referred to by the letter designation SCR, which in the usual sense, refers to.

a controlled rectifier having NPNP junctions comprising silicon. However, it is contemplated by applicant that other types of controlled rectifiers can be substituted in the circuit, provided the response time is sufficiently fast.

The pulse transformer trigger circuit 8 comprises a pair of pulse transformers 10 and 11 which deliver signals alternately to the opposite polarity portions of the switching circuit 9. The trigger circuit 8 is similar to the timing circuit illustrated and described at p. 200 of the General Electric Transistor Manual, sixth edition of the above reference, to produce a variable adjustment to the square wave output signal. The trigger circiut is also described generally in US. Patent 3,075,136, issued on Jan. 22, 1963, to D. V. Jones. The circuit has been further modified by the addition of two booster SCRs I 12, 13 to insure sufiicient signal strength to pulse transformers 10, 11 for multiple SCR firing.

The pulse transformer'trigger circuit 8 comprises a cross-coupled flip-flop circuit including transistors 14, 15, unijunction transistor 16, adjustable potentiometer 17, 18, coupling capacitors 19, 20, and resistors 21, 22. The trigger circuit 8 is electrically connected to a transformer 23. The potentiometers 17 and 18 have been shown as adjustable in the drawing to illustrate that they are capable of being programmed by any well known sequence programming device, such as a magnetic tape or the like, which is operatively connected to adjust the potentiom eters 17, 18 in accordance with a predetermined program sequence.

The transistors 14, 15 are gating transistors for diode capacitor type gate steering. Each transistor 14, 15 has its emitter 23, 25 connected to base two electrode 26 of unijunction transistor 16, and base one electrode 27, 28 of transistor 14, 15 is cross-coupled to the opposite transitsor 15, 14 and collector 29, 20 through a crosscoupling capacitor 31, 32 and cross-coupling resistor 33, 34 disposed in parallel.

The base one leg 35 of the unijunction transistor 16 is also parallel connected to the collectors 29, 30 through resistors 36, 37 and center tap connected to the secondary 38 of supply transformer 23. Primary 39 of transformer 23 is connected to a source of 110 v., 60 cycle alternating current (not shown).

Anode 40, 41 of booster SCR12, 13 is connected to a switching capacitor 42, 43 having a resistor 44, 45 disposed in parallel therewith and from there, back to transformer secondary 38, through resistors 46, 4'7 and blocking diodes 48, 49. Gate 50, 51 of booster SCR12, 13 is connected to coupling'capacitor 19, 26, resistor 21, 22, and to the regulating potentiometer 17, 18. Base 52, 53 of SCR12, 13 is connected to primary 54, 55 of pulse transformer 10, 11.

Capacitor 56, 57 is disposed in parallel with the power supply of circuit 8, and in series with resistance 46, 47, respectively, which is center tapped to secondary 33. A Zener diode 58 is also provided in parallel with capacitor 56, 57 to provide a steady D.C. source for the trigger system.

A timing capacitor 59 is connected in series with emitter 60 of unijunction transistor 16. Capacitor 59 is connected through lead 61 between a small resistor 62 and a larger resistor 63. The resistor 63 is connected to the emitter 25 of transistor 15 at its other terminal. Small resistors 64, 65 are included between the base one electrodes 27, 28 of transistors 14, 15 and the secondary 38 of transformer 23. A resistor 66 is disposed in series between the base two electrode 26 of unijunction transistor 16 and the emitter 24 of PNP transistor 14. Another resistor 67 is disposed in series with emitter 60 of unijunction transistor 16, and is connected between two silicon diode rectifiers 68, 69.

In operation, a direct current energizing signal is supplied through transformer 23, rectifiers 48, 49, R-C filters 46, 56 and 47, 57, resistor 62, and timing capacitor 59 to the emitter 60 of the unijunction transistor 16. Base one leg 35 of unijunction transistor 16 is at ground potential,

and a positivebi'as voltage appears at base two leg 26 through resistor 63 from transformer 23. When timing ca pacitor 59 discharges, the emitter voltage exceeds the voltage appearing at the base two leg 26, the emitter 60'becomes forward biased and a negative current pulse flows to the collector-24, 25 of PNP transistor 14, 15, depending on their condition at the particular instant of time. The

' signal to collector 24, 25 causes the transistor 14, 15 to conduct, supplying. a turn-off signal for the opposite transistor 14, through resistor 33, 34 and capacitor 31, 32 and supplying a gate signal to turn on the associated booster SCR12, 13 through coupling capacitor 19, and coupling resistor 21, 22. When transistor 14, 15 conducts, it also completes the circuit through variable potentiometer 17, 18, diode 68, 69, and resistor 67 to emitter 60 of unijunction transistor 16 so that the cycle may be repeated in typical flip-flop, bistable multi-vibrator operation. The particular square wave generator shown can be varied in pulse width by independent adjustment of the potentiometers 17 and 18.

The gate signal to booster SCR12, 13 triggers full rated current conduction of SCR12, 13 through switching capacitor 42, 43 and switching resistor 44, 45 to provide a signal pulse to primary 54, of pulse transformer 10', 11.

Booster SCR12, 13 is turned off when the anode current drops below the SCR minimum holding current, due to nearly charged capacitor 42 or 43. When the SCR turns off, capacitors 42 or 43 will be discharged to zero with resistor 44 or 45. The SCR is now ready to receive the next gate pulse from the transistor bistable multivibrator.

The pulse signal transmitted through pulse transformer 10, 11 provides accurate triggering means for the power source control circuit 3 to switch the load between power sources 1 and 2.

Control circuit 3 includes a positive voltage network and a negative voltage network 71 which allow power sources 1 and 2, respectively, to synthesize a square wave, alternating current through the welding electrode 7, which is connected through common lead 72 to networks 70 and 71.

An alternating polarity arc is struck through a workpiece 73, which is held at zero potential through common ground 5, and a common ground conductor 74, which is connected between power sources 1 and 2 to the negative pole 4 of power source 1 and positive pole 75 of power source 2.

The positive network 70 and the negative network 71 are identical in function but opposite in polarity. Network 70, 71 is triggered through pulse transformer 10, 11.

Network 70, 71 includes a plurality of small turn-off SCRs 76, 77 (78, 79), each having its gate 80, 81 (82. 83) connected across a resistor 84, 85 (86, 87) to a secondary winding 88, 89 (90, 91) of pulse transformer 10, 11. The other end of secondary winding 88, 89 (90, 91) is connected to cathode lead 92, 93 (94, 95) of turn-off SCRs 76, 77 (78, 79).

A suitable constant potential auxiliary power source 96, 97 is provided to assure full charging of commutating capacitors 126, 127 (128, 129). When the capacitors 126, 127 (128, 129) are fully charged, they will be caused to discharge when the associated turn-off SCRs 76, 77 (78, 79) conduct. When turn-off SCRs 76, 77 (78, 79) conduct when their gates 80, 81 (82, 83) receive a pulse from the associated pulse transformer 10, 11. This turnon signal pulse for the SCRs 76, 77 (78, 79) originates in the pulse transformer trigger circuit 8.

Therefore, in this way, SCRs 76, 77 (78, 79) control the turn-off of their associated load SCRs 98, 99 (100, 101), because when SCRs 7'6, 77 78, 79) conduct, capacitors 126, 127 (128, 129) cause a reverse potential to appear across the associated load SCRs 98, 99 (100, 101), thereby shoving their anodes negative with respect to their cathodes. Capacitors 126, 127 (128, 129) and auxiliary power source 96, 97 are selected to provide a back biasing voltage of sufficient duration to assure turn-off of the associated load SCRs 98, 99 (100, 101), because it is imperative that one half of the circuit be turned off before the other half is permitted to conduct to avoid destruction of the SCRs.

Turn-on of the load SCRs (100, 101) 98, 99 is accomplished by means of a load pulse transformer 114,

having its primary 116, 117 associated with one of the opposite polarity load SCRs 101, 99, and with the turnoff SCRs 76, 77 (78, 79). Secondary windings 118, 119 (120, 121) are connected across cathodes 122, 123 (124, 125) of the load SCRs 98, 99 (100, 101) and when the respective turn-01f SCRs 76, 77 (78, 79) conduct, a turnon signal is automatically provided to turn on the opposite polarity load SCRs just as the conducting load SCRs are being back biased to turn them off. At this instant, load switching is accomplished without waiting for charge carriers to clear junctions of the SCR that is being turned oiT.

Each turn-off SCR76, 77 (78, 79) has a capacitor 126, 127 (128, 129) connected to its load SCR98, 99 (100, 101) in such a manner that conduction of the turn-off SCR will place the charge in the capacitor across its associated load SCR, making the anode negative with respect to its cathode. Current limiting resistors 130, 131, 132, 133 (134, 135, 136, 137) are provided between the power source 96, 97, the turn-off SCRs 76, 77 (78, 79) and the load SCRs 98, 99 (100, 101). Capacitor 138, 139 is provided in series between the auxiliary power source 96, 97 and main power source 1, 2. Also, auxiliary power source 96, 97 includes rectifier diodes 140, 141 (142, 143). A current limiting resistor 144, 144a is also provided between the transformer 114, 115 and the capacitor 127, 129 to protect the transformer 114, 115 and the SCR gates 110, 111 (112, 113) from excessive current surges. A rectifier diode 146, 147 is provided in a shunt circuit 146a, 147a around power sources 1 and 2, to prevent voltage reversal during fast transients.

Voltage adjustment of power sources 1 and 2 is accomplished independently by means of the conventional controls provided with them (not shown). Resistor 148, 149 is connected through an overload coil 150, 151 in parallel with a pair of small rectifier diodes 154, 155 (156, 157), and is part of the overload protection circuit.

Main power sources 1 and 2 can also be turned on and 0E by means of main contactors 158, 159.

Zener diodes 160, 161 (162, 163) are provided at the gates 110, 111 (112, 113) in parallel with the filtering capacitor 102, 103 (104, 105) to prevent transient voltages from erroneously signaling the load SCR98, 99 (100, 101) and to limit the gate voltage to the Zener voltage. Small diodes 164, 165 are provided between ground 166, 167 and the primary 116, 117 of pulse transformer 114, 115. Capacitance 168, 169 is connected from common ground lead 74 and ground 5 to power source 1, 2 through cont-acts 158, 159.

It is, of course, contemplated that the above described circuit could be modified and still provide a power source which can be rapidly switched from one polarity to the opposite to produce a square wave, alternating current most suitable for arc welding.

The operation of the trigger circuit 8 has been described above. The operation of the control circuit 3 will now be described.

The main control circuit 3 is energized by closing contacts 158, 159 energizing power sources 1, 2, which in turn energize power sources 96, 97. Pulses received through pulse transformer 10, 11 trigger the respective gates of turn-off SCRs 76, 77 (78, 79).

When turn-01f SCRs 76, 77 (78, 79) conduit, they connect capacitors 126, 127 (128, 129) to their associated load SCRs 98, 99 (100, 101) back biasing them, and causing them to turn off. The same signal which turns off the load SCRs 98, 99 (100, 101) automatically provides a turn-on pulse through pulse transformer 114, 115 and diodes 164, 165 to turn on the opposite load SCRs 100, 101 (98, 99). When the load SCRs 98, 99 (100, 101) conduct load current, they complete an electrical circuit through the power source 1 (2), resistors 132, 133 (136, 137) and through electrode 7, thereby providing an alternating square wave electric current to electrode 7. The

7 electrode 7 is disposed close enough to workpiece 73 to establish an alternating current are therebetween.

Applicant has discovered that excellent welding results can be obtained with an alternating current, square wave welding power source. The manipulation of the positive and negative pulse duration compensates for many problems found in straight direct current welding. Also, various vare steel electrodes, which could not be used with alternating current power sources at all, can now be used very etfectively with applicants rapid rise time, square wave power source.

The rise time is critical in re-estab-lishing the are after the arc outage period when the current and voltage goes through zero on each cycle. The rise time obtainable with the above described circuit falls well within the range of -20 microseconds from zero to 151.111 on. Applicant has found that the rise time range will permit welding even with the most difficult and unstable electrodes.

Other benefits in the way of increased deposition rate, more stable welding are, better and smoother weld deposits, have been accomplished by means of the invention.

The power concept of arc Welding disclosed in this invention makes it possible to accomplish many difficult welding operations, such as overhead welding, by simply adjusting the power source. Even the most amateur weldor is able to make good welds the first time because of power source automatic adjustment.

Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.

1 claim:

1. A method of consumable, continuous electrode arc welding with a power source capable of producing positive and negative current pulses of predetermined duration, said power source including control means for varying both voltage and current independently and for varying each successive current pulse completely independently of the other pulses in the sequence, including the steps of pre-programming the power source control means to produce a predetermined sequence of positive and negative current pulses of predetermined potential when the arc welding cycle is initiated on a workpiece, feeding the tip of said continuous electrode at a constant speed towards said workpiece while moving said tip and said Workpiece relative to each other in a direction and speed to initiate and maintain an alternating current are between said electrode and said workpiece, said are having a predetermined sequence of current and voltage pulses each pulse being independently controlled, and changing the predetermined sequence of positive and negative current pulses automatically during welding when the welding conditions are changed during the course of Welding.

2. A method of controlled power arc welding including the steps of pre programming a predetermined sequence of welding power pulses into a welding power source, said power source including rectifier diodes of the low loss type and having control means incorporating controlled rectifiers to produce a substantial range of variation of voltage and current in harmony with particular welding conditions, connecting said power source in cirsuit with a constant feed, continuous consumable electrode and a workpiece, initiating an are between said electrode and the workpiece, moving said electrode and said workpiece relative to each other at a constant speed while the are therebetween is automatically controlled by the predetermined sequence of welding power pulses, and changing the power pulse sequence as the orientation of said workpiece to said elect-rode changes to thereby immediately adjust the power supplied to said are to the new welding conditions.

References Cited UNITED STATES PATENTS 1,612,084 12/1926 Weed 3l5-12l 2,694,764 11/1954 Muller 219-74 2,697,160 12/1954 Williams 219--l35 2,951,930 9/1960 McKechnie 219-69 3,068,352 12/1962 Correy 219-137 3,150,312 9/1964 Willecke 219131 X 3,219,881 11/1965 R-udaz 219-131 X 3,330,933 7/1967 Maklary 219-131 OTHER REFERENCES Turnball: Selected Harmonic Reduction in Static D.C. A.C. Inverters, I.E.E.E., July 1964, paper 63-1011, delivered June 162l, 1963, pp. 374-378 relied on.

RICHARD M. WOOD, Primary Examiner.

J. G. SMITH, Assistant Examiner. 

1. A METHOD OF CONSUMABLE, CONTINUOUS ELECTRODE ARC WELDING WITH A POWER SOURCE CAPABLE OF PRODUCING POSITIVE AND NEGATIVE CURRENT PULSES OF PREDETERMINED DURATION, SAID POWER SOURCE INCLUDING CONTROL MEANS FOR VARYING BOTH VOLTAGE AND CURRENT INDEPENDENTLY AND FOR VARYING EACH SUCCESSIVE CURRENT PULSE COMPLETELY INDEPENDENTLY OF THE OTHER PULSES IN THE SEQUENCE, INCLUDING THE STEPS OF PRE-PROGRAMMING THE POWER SOURCE CONTROL MEANS TO PRODUCE A PREDETERMINED SEQUENCE OF POSITIVE AND NEGATIVE CURRENT PULSES OF PREDETERMINED POTENTIAL WHEN THE ARC WELDING CYCLE IS INITIATED ON A WORKPIECE, FEEDING THE TIP OF SAID CONTINUOUS ELECTRODE AT A CONSTANT SPEED TOWARDS SAID WORKPIECE WHILE MOVING SAID TIP AND SAID WORKPIECE RELATIVE TO EACH OTHER IN A DIRECTION AND SPEED TO INITIATE AND MAINTAIN AN ALTERNATING CURRENT ARC BETWEEN 